Structures and sensor assemblies having engagement structures for securing a compliant substrate assembly

ABSTRACT

Structures and sensor assemblies having engagement structures for securing a compliant substrate assembly are disclosed. In one embodiment, a sensor assembly includes a compliant substrate assembly having a base layer, and a deformable layer heat-sealed to the base layer such that the base layer and the deformable layer define at least one inflatable chamber. The sensor assembly further includes a first member proximate to a first edge of the compliant substrate assembly, a second member proximate to a second edge of the compliant substrate assembly, wherein the second edge is opposite the first edge, and at least one pressure sensor fluidly coupled to the at least one inflatable chamber and operable to produce a signal indicative of a pressure within the at least one inflatable chamber.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional PatentApplication 63/272,824 filed on Oct. 28, 2021 and entitled “SoftTactile-sensing Upper-body Robot for Large Object Manipulation andPhysical Human Interaction,” which is hereby incorporated by referencein its entirety.

TECHNICAL FIELD

The present specification generally relates to sensors and, moreparticularly, to structures and sensor assemblies having engagementstructures for securing a compliant substrate assembly.

BACKGROUND

There are many problems that should be solved before robust roboticmanipulation finds its way into our homes and daily lives. Many avenuesof manipulation research rely on gripper-only grasps and interactions.While many objects are designed to be held, grasped, or used with ourhands, humans manipulate larger objects using their whole bodies on adaily basis with natural, contact-rich actions. Arms, chests, and otherareas of the body are frequently used to carry and stabilize large orheavy objects, piles of items, or delicate items that require a gentledistribution of pressure. Research has shown that older adults need andwant assistance with lifting and carrying large and heavy objects; atype of assistance that may allow them to live independently longer.Co-developing effective hardware and control strategies for these kindsof whole-body manipulation tasks greatly expands the capabilities ofrobots, especially for assisting people in their homes.

Whole-body manipulation is a challenge that requires innovativesolutions in both hardware and control. Accordingly, a need exists foralternative robotic hardware and control methods for whole body objectmanipulation.

SUMMARY

In one embodiment, a sensor assembly includes a compliant substrateassembly having a base layer, and a deformable layer heat-sealed to thebase layer such that the base layer and the deformable layer define atleast one inflatable chamber. The sensor assembly further includes afirst member proximate to a first edge of the compliant substrateassembly, a second member proximate to a second edge of the compliantsubstrate assembly, wherein the second edge is opposite the first edge,and at least one pressure sensor fluidly coupled to the at least oneinflatable chamber and operable to produce a signal indicative of apressure within the at least one inflatable chamber.

In another embodiment, a structure for receiving a compliant substrateassembly includes an outer surface, a first set of engagement featuresextending from a first location of the outer surface, wherein the firstset of engagement features are configured to receive a first member ofthe compliant substrate assembly, and a second set of engagementfeatures extending from a second location of the outer surface that isoffset from the first location by a distance, wherein the second set ofengagement features are configured to receive a second member of thecompliant substrate assembly.

In yet another embodiment, a sensor assembly includes a base structureincluding an outer surface, a first set of engagement features extendingfrom a first location of the outer surface, and a second set ofengagement features extending from a second location of the outersurface that is offset from the first location by a distance. The sensorassembly further includes a compliant substrate assembly including abase layer, a deformable layer heat-sealed to the base layer such thatthe base layer and the deformable layer define at least one inflatablechamber, a first member proximate to a first edge of the compliantsubstrate assembly, wherein the first member is held by the first set ofengagement features, and a second member proximate to a second edge ofthe compliant substrate assembly, wherein the second edge is oppositethe first edge and the second member is held by the second set ofengagement features such that the compliant substrate assembly isstretched over at least a portion of the base structure. The sensorassembly further includes at least one pressure sensor fluidly coupledto the at least one inflatable chamber and operable to produce a signalindicative of a pressure within the at least one inflatable chamber.

These and additional features provided by the embodiments describedherein will be more fully understood in view of the following detaileddescription, in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments set forth in the drawings are illustrative and exemplaryin nature and not intended to limit the subject matter defined by theclaims. The following detailed description of the illustrativeembodiments can be understood when read in conjunction with thefollowing drawings, where like structure is indicated with likereference numerals and in which:

FIG. 1 schematically depicts a perspective view of an example robotaccording to one or more embodiments described and illustrated herein;

FIG. 2 schematically depicts a side view of the robot illustrated byFIG. 1 according to one or more embodiments described and illustratedherein;

FIG. 3 schematically depicts a perspective view of the robot illustratedby FIG. 1 with its arms raised according to one or more embodimentsdescribed and illustrated herein;

FIG. 4 schematically depicts a perspective view of the robot illustratedby FIG. 1 with its arms in a grasping position according to one or moreembodiments described and illustrated herein;

FIG. 5 schematically depicts a front view of a body structure of therobot illustrated by FIG. 1 having a cover removed according to one ormore embodiments described and illustrated herein;

FIG. 6A schematically depicts a perspective view of an illustrativeflexible tactile sensor according to one or more embodiments describedand illustrated herein;

FIG. 6B schematically depicts a top-down view of an illustrative coilarrangement for a flexible tactile sensor according to one or moreembodiments described and illustrated herein;

FIG. 6C schematically depicts a top-down view of an illustrative coilarrangement on a printed circuit board and positioned below a conductivetarget of a flexible tactile sensor according to one or more embodimentsdescribed and illustrated herein;

FIG. 6D schematically depicts a perspective side view of an illustrativecoil arrangement positioned below a conductive target of a flexibletactile sensor according to one or more embodiments described andillustrated herein;

FIG. 6E schematically depicts a perspective view of an illustrativeflexible tactile sensor having a modular flexible layer according to oneor more embodiments described and illustrated herein;

FIG. 6F schematically depicts a bottom perspective view of a connectingmeans for coupling two or more flexible tactile sensor modules accordingto one or more embodiments described and illustrated herein;

FIG. 6G schematically depicts an illustrative diagram of a magneticfield of a coil interacting with a conductive target according to one ormore embodiments described and illustrated herein;

FIG. 7 schematically depicts front view of an array of flexible tactilesensors of a body structure of a robot 1 according to one or moreembodiments described and illustrated herein;

FIG. 8 schematically depicts rear view of the body structure illustratedby FIG. 7 according to one or more embodiments described and illustratedherein;

FIG. 9A schematically depicts a side view of an example body structureof a robot in an upright position 1 according to one or more embodimentsdescribed and illustrated herein;

FIG. 9B schematically depicts a side view of the example body structureillustrated by FIG. 9A in a tilted position 1 according to one or moreembodiments described and illustrated herein;

FIG. 10 schematically depicts an example robot holding a hamper with itsarms according to one or more embodiments described and illustratedherein;

FIG. 11 schematically depicts an example deformable sensor according toone or more embodiments described and illustrated herein;

FIG. 12 schematically depicts a deformable sensor on a rigid segment ofa robot arm according to one or more embodiments described andillustrated herein;

FIG. 13 schematically depicts a top-down view of an assembly providingan array of sensor according to one or more embodiments described andillustrated herein;

FIG. 14 schematically depicts a perspective view of the assembly of FIG.13 disposed on an inflatable sensor according to one or more embodimentsdescribed and illustrated herein;

FIG. 15 schematically depicts a plurality of inflatable sensors disposedon segments of a robot arm according to one or more embodimentsdescribed and illustrated herein;

FIG. 16 schematically depicts members for preventing movement of adeformable sensor on a robot arm according to one or more embodimentsdescribed and illustrated herein;

FIG. 17 schematically depicts the member shown in FIG. 16 and furtherincluding friction tape according to one or more embodiments describedand illustrated herein;

FIG. 18 schematically depicts a cross-sectional view of an example rigidsegment and members for preventing movement of a deformable sensoraccording to one or more embodiments described and illustrated herein;

FIG. 19 schematically depicts a cross-sectional view of another examplerigid segment and members for preventing movement of a deformable sensoraccording to one or more embodiments described and illustrated herein;

FIG. 20 schematically depicts an example pressure sensor deviceaccording to one or more embodiments described and illustrated herein;

FIGS. 21A and 21B schematically depict another example pressure sensordevice according to one or more embodiments described and illustratedherein;

FIGS. 22A-22C schematically depict another example pressure sensordevice according to one or more embodiments described and illustratedherein;

FIG. 23 schematically depicts another example pressure sensor deviceconfigured as a cube according to one or more embodiments described andillustrated herein;

FIG. 24 schematically depicts a sensor assembly disposed on a rigidsegment of a robot according to one or more embodiments described andillustrated herein;

FIG. 25 schematically depicts rigid segments of a robot configured tohold soft sensor assemblies according to one or more embodimentsdescribed and illustrated herein; and

FIG. 26 schematically depicts soft sensor assemblies disposed on therigid segments of the robot depicted by FIG. 25 .

DETAILED DESCRIPTION

Referring generally to the appended figures, embodiments of the presentdisclosure are directed to structures and sensor devices havingengagement features that are used to secure a compliant substrateassembly, such as a compliant substrate assembly that forms a part of acompliant sensor.

Unsurprisingly, older adults have difficulty with lifting and carryinglarge, bulky and/or heavy objects; “heavy” can be quantified as 10 lbs/5kg as defined by PROMIS® or as “groceries” in the SF-36 PhysicalFunction. As people age, they experience a decrease in their mobilityand stability, which are key to being able to lift and carry theseobjects. Older adults are reluctant to accept or ask for help from aperson as relying on someone else (e.g., familial caregiver, homehealthaide) can decreases their sense of independence. Some older adultseven discontinue the use or purchase of large, bulky, or heavy objects,which maintains their independence with a slightly reduced quality oflife. Some older adults are open to the idea of robotic technologyphysically assisting them, especially in Japan where the ratio of olderadults to young adults is 1:2.

When it comes to maintaining contact and regulating object state duringgrasping and manipulation, the present inventors have found thatincorporating under-actuated mechanisms, joint and surface compliance,and friction offers tremendous gains in manipulation robustness.Effectively using compliant contacts all over the body is demonstratedby pressure-based feedback informed grasping of unmodeled objects.Inspired by these ideas, a gripper known as a soft bubble gripper,incorporates highly compliant tactile sensing fingers and not onlymaintains passively stable grasps but leverages multi-modal sensing todetect contact and manipuland state. The soft bubble gripper isdescribed in U.S. Pat. No. 10,668,627, which is hereby incorporated byreference in its entirety.

In embodiments of the present disclosure, hard robots are equipped withdurable, highly compliant, tactile sensing surfaces to enable morecapable, contact-rich manipulation with minimal reliance on advancedcontrol strategies. Embodiments also provide grasping methodologies thattake advantage of softness and tactile sensing for whole-body graspingand lifting, object manipulation, and contact-rich physical human-robotinteraction. Contact-rich, whole arm manipulation of objects includeschallenges, such as accounting for the resulting closed-kinematic chainsof multiple arms making and maintaining contact with a target geometry,enumerating and maintaining rich contact (more than two independentcontact regions) with the target object, accounting for the surfacefrictional and compliance properties of the contact, and observing thestate of the manipuland and the contact area, among others.

Various tactile sensing skins that monitor contact with objects thathave been developed for both robot grippers and for the entire body ofthe robot are disclosed. This potentially enables whole-body physicalinteraction with humans and the environment, and is a promising solutionfor multi-contact control, as evidenced by results on monitoring contactpatch geometries and in developing manipulation primitives.

Embodiments provide for an approach for augmenting off-the-shelf hardrobot platforms with surface compliance and tactile sensing. With astrong focus on exploiting mechanical intelligence, embodiments enablerobust and effective whole-body manipulation for large, unmodeleddomestic objects with comparatively simpler tactile feedback- basedcontrol strategies.

Various embodiments for structures and sensors having engagementfeatures for securing a compliant substrate assembly, such as acompliant substrate assembly used in a compliant sensor used for tactilesensing, are described in detail below.

Referring now to FIGS. 1-4 , a non-limiting example robot 100 capable oflifting large, heavy objects by full-body, contact rich manipulation isillustrated. FIG. 1 is a front perspective view of the robot 100. FIG. 2is a side view of the robot. FIG. 3 is a front perspective view of therobot 100 with its arms 130 raised, and FIG. 4 is a front perspectiveview with the arms 130 of the robot in a grasping position. It should beunderstood that embodiments of the present disclosure are not limited bythe robot 100 illustrated by FIGS. 1-4 and that other configurations arealso possible.

Generally, the robot 100 is configured as a soft, bimanual upper-bodyplatform for large object manipulation. The robot 100 comprises a railsystem 110, a base (which is defined by base members 113), a bodystructure 120 coupled to the rail system 110, and two arms 130 coupledto the body structure 120. As described in more detail below, the bodystructure 120 acts as the “chest” of the robot 100 in a similar manneras a chest of a human, which can be used for supporting large objects.

The rail system 110 includes a vertical rail 111 that extends in asystem direction (e.g., a system vertical direction) on which the bodystructure 120 and the two arms 130 may traverse to be raised andlowered. The robot 100 further includes a lift actuator 125 (FIG. 2 )that is operable to raise and lower the body structure 120 and thus thetwo arms 130 on the vertical rail 111. The lift actuator 125 may be anyactuator capable of raising and lowering the body structure 120.Non-limiting examples of the lift actuator 125 include a linear motorand a rack and pinion linear actuator. In other embodiments, the liftactuator 125 may be manual such that a human operator may raise andlower the body structure 120 on the vertical rail 111.

The vertical rail 111 and lift actuator 125 allows for the adjustment ofthe body structure 120 to a specific grasping height. The base of thebody structure 120 can travel vertically from the floor to a maximumheight (e.g., 140 cm). The body structure 120 and the lift actuator 125sit on the base members 113, which have passive casters 114. The basemembers 113 may also support a control computer and other electronics.With a power and networking bundle running off the platform, the robot100 can be wheeled around to transfer grasped objects from one locationto another. For example, the robot 100 may include handlebars 170 thatmay be grasped by the user to push and pull the robot in the operatingenvironment. Thus, embodiments provide a robot 100 defining a mobilemanipulation platform, either wheeled or legged, without distractingdevelopment focus from the core manipulation goals being explored.Further, the human element prevents a reliance on ground truth knowledgeof the manipuland’s state, forcing an embrace of tactile-driven feedbackcontrol.

Although the illustrated robot 100 is shown as having passive casters114, it should be understood that embodiments described herein may havemotorized wheels, tracks or other components configured to eitherremotely control the robot 100 or provide for an autonomous robot 100that may maneuver an environment autonomously.

The robot 100 may also include a cabinet 160 to house computing devices,sensors, and other electronic components.

The two arms 130 and the body structure 120 are mounted in-line on thevertical rail 111 so that the shoulder width of the robot 100 can beadjusted at any time. In the illustrated embodiment, the bottom of thebody structure 120 aligns with the base of the arms. The configurationof the arms 130 and the body structure 120 relative to one another,particularly the shoulder angles, impacts the whole-body manipulationworkspace.

Referring now to FIG. 5 , a front view of the body structure 120 of theexample robot 100 of FIGS. 1-4 is schematically illustrated. The examplebody structure 120 comprises an array of flexible tactile sensors 127that is optionally covered by a cover 129. The cover 129 may befabricated from a friction material that increases the coefficient offriction between the body structure 120 and an object over thecoefficient of friction between the array of flexible tactile sensors127 and the same object. The cover 129 may be fabricated from a durablematerial such that it protects the array of flexible tactile sensors127.

As a non-limiting example, the cover 129 may be a neoprene cover stripedin high-friction tape (e.g., 3M TB641 manufactured by 3M). The neoprenematerial creates a smooth, uniform surface over the entire array offlexible tactile sensors 127, providing a protective layerfor theflexible tactile sensors 127 and bridging gaps between the individualflexible tactile sensors 127. Meanwhile, the friction tape provides ahigh friction surface for objects to interface with during manipulation,thereby reducing the load carried by the arms 130 during a grasp.

Each flexible tactile sensor 127 of the array of flexible tactilesensors 127 is operable to produce a signal that is determinative of amagnitude and a direction of a force applied to the flexible tactilesensor 127 (i.e., a directional force vector). The flexible tactilesensors 127 are “flexible” in that they are capable of being deformedwhen a force is applied thereto. As each individual flexible tactilesensor provides an individual directional force vector when an object ispressed against the body structure 120, the geometric shape and/or poseof the object may be determined. For example, a trained model may beutilized to receive the individual directional force vectors and outputa geometric shape and pose of an object pressed against the bodystructure 120. The data from the array of flexible tactile sensors 127may be used to manipulate objects by using the arms 130 to press anobject, such as a hamper 199, against the body structure 120.

Turning to FIG. 6A, a perspective view of an illustrative flexibletactile sensor 127 according to one or more embodiments is depicted. Itshould be understood that embodiments are not limited by the shape andconfiguration of the example flexible tactile sensor 127 shown in FIG.6A. Some embodiments of the flexible tactile sensor 127 include ahousing having an upper structure 10 coupled to a lower structure 12forming a cavity therebetween. A print circuit board (PCB) 20 ispositioned within the cavity of the housing. The PCB 20, as described inmore detail herein, may include a plurality of coils 25 and/or otherelectronic components for enabling the sensing functionality of theflexible tactile sensor 127. The flexible tactile sensor 127 furtherincludes a pliable material 30 coupled directly to the plurality ofcoils 25 or to the upper structure 10 of the housing including the PCB20. The pliable material 30 may be any material that is capable ofelastically deforming under an applied force. That is, the pliablematerial 30 may temporarily deform and then return to an initial formwhen applied contact forces are removed. The pliable material 30 may bemade up of one or more materials or may be a mechanical structure havingmembers that are capable of flexing, folding, bending or the like undera contact force then returning to an initial state without permanentdeformation. An example mechanical structure type of pliable material 30is depicted and described herein with reference to FIG. 6E.

Still referring to FIG. 6A, the pliable material 30 is further coupledto a conductive target 40. The conductive target 40 is a metal plate orsimilar material that is spaced apart from the plurality of coils 25 bythe pliable material 30. The conductive target 40 may be a metal plateor composite material having a conductive layer that interacts with themagnetic fields generated by the plurality of coils 25. The conductivetarget has a thickness that is greater than the skin depth of theelectric field created in response to the electromagnetic fieldgenerated by the plurality of coils 25. This is to ensure that thesensors are responding to the conductive target 40 and theelectromagnetic field is not effectively going through the conductivetarget 40 and responding to conductive items beyond the conductivetarget 40.

The conductive target 40 has a first surface 40A and a second surface40B. In embodiments, the surface area of at least the second surface 40Bof the conductive target 40 which is oriented to face the plurality ofcoils 25 has a surface area that is greater than at least one of theplurality of coils 25 and when in a non-contact position extends overone or more of the plurality of coils 25. The second surface 40B iscoupled to the pliable material 30. The pliable material 30 enables theconductive target 40 to move with respect to the plurality of coils 25in response to contact forces applied thereto. For example, the pliablematerial 30 may compress, twist, translate, or otherwise cause theconductive target 40 to move in response to applied contact forces.

In some embodiments, the conductive target 40 includes a compliantmaterial 45. The compliant material 45 may be coupled to and/or formedover a portion of the conductive target 40. The compliant material 45may be generally applied to the surface of the conductive target 40 thatis opposite the surface coupled to the pliable material 30. Thecompliant material 45 may be a neoprene, rubber-like, latex, or similarmaterial that assists in providing a friction surface for shear forcesor other non-perpendicular forces applied to the surface of theconductive target 40. In some embodiments, the compliant material 45 mayextend over the surface of the conductive target 40 and the pliablematerial 30 thereby coupling to the housing (e.g., the upper structure10) to constrain the conductive target 40 and the pliable material 30 inthe X-Y directions. This configuration may also be used to pre-compressthe pliable material 30. It should be understood that the compliantmaterial 45 is not provided in some embodiments.

The housing may further include openings 22 in either or both the upperstructure 10 and/or the lower structure. The openings 22 may provideaccess to connections between flexible tactile sensor 127 modules and/orcomputing devices. The connections may be electrical and/or mechanical.Electrical connections may be facilitated by electrical terminaldisposed on the PCB 20 within the housing and wiring harnesses andmating connectors extending through the openings. Mechanical connectionsmay be implemented to connect multiple flexible tactile sensor 127modules together in a row, a column, or an array. In other embodiments,no openings are provided.

The lower structure 12 of the housing includes the PCB 20 and otherelectronic components. In some embodiments, a ferrite material (notshown) may be positioned between the PCB 20 and the lower structure 12.The ferrite material may be in the form of a sheet and configured toconstrain the electromagnetic field created by the plurality of coils 25disposed in or on the PCB 20. This concentrates the magnetic flux andredirects it toward the conductive target 40, which may also increasethe range of the sensor. In some embodiments, a ferrite material may beapplied to the first surface 40A of the conductive target 40. Theapplication of a ferrite material on the first surface 40A of theconductive target 40 may further help prevent the plurality of coils 25from sensing beyond the conductive target 40. This may be beneficialwhen objects that the flexible tactile sensor 127 is interfacing withare large metallic objects such as pots and pans.

Turning to FIG. 6B, a top-down view of an illustrative coil arrangementfor a flexible tactile sensor is depicted. Coil arrangements of thepresent disclosure include at least three coils arranged in a planararray configuration with each other. FIG. 6B depicts a PCB 20 thatincludes four coils 25A, 25B, 25C, and 25D. The coils 25A-25D(collectively referenced as coils 25) may be configured on or within thePCB 20. That is, the coils 25 may be formed on the surface of the PCB 20as a layer of the PCB 20 or the coils may be formed and/or embedded withthe PCB 20. The coils are planar coils having a predetermined number ofturns. Configurations of three or more coils 25 enable rich sensinghaving multiple points of measurement. That is, compound rotations aboutthe X and Y-axes enable the sensor to measure the normal force vector.

Turning to FIG. 6C, the top-down view of the flexible tactile sensordepicted in FIG. 6B now shows the conductive target 40. The conductivetarget 40 as described herein, is positioned, for example, in verticalalignment with the plurality of coils 25 such that a portion of theconductive target 40 vertically aligns with the plurality of coils 25.The flexible tactile sensor depicted in FIG. 6C is in a contactlessstate. Additionally, the conductive target 40 is depicted as a circulardisc. However, in other embodiments, the conductive target 40 may haveother shapes such as a triangular plate or a square plate. The shape ofthe conductive target 40 may be selected in conjunction with thearrangement of the array of three or more coils 25. FIG. 6D depicts aperspective side view of the illustrative coils 25 and conductive target40 depicted in FIG. 6C. Here, FIG. 6D shows that the conductive target40 is spaced apart from the coils 25 by a height H. The spacing betweenthe conductive target 40 and the coils 25 may be occupied by the pliablematerial 30, which enables the conductive target 40 to move with respectto the coils 25. As described in more detail herein, as the respectiveheight between the conductive target 40 and select coils 25 changes theinductance of the coils changes, which may be sensed and used todetermine the change in position of the conductive target 40.

Turning to FIG. 6E, a perspective view of an illustrative flexibletactile sensor 127. In particular, the embodiment depicted in FIG. 6Eincludes a non-limiting example of a modular flexible layer 50 forming amechanical structure type of pliable material 30. For example, thepliable material 30 may be a 3D-printed, molded, machined, or otherwiseformed structure. The modular flexible layer 50 functioning as thepliable material 30 portion of the flexible tactile sensor 127 maycomprise a plurality of interlocking segments 50A, 50B, 50C, and 50Dthat can independently flex thereby enabling the modular flexible layer50 to support the conductive target 40 (not shown in FIG. 6E) andrespond to forces applied to the conductive target 40. For example, eachof the plurality of interlocking segments 50A, 50B, 50C, and 50Dincludes a first surface 51 opposite a second surface 53. The firstsurface 51 and the second surface 53 are interconnected by a pluralityof flexible members 52. The plurality of flexible members 52 may beconfigured to bend, flex, or fold when stressed and return to a relaxedpositioned when the source of stresses are removed. For example, theplurality of flexible members 52 may be rib shaped structures extendingfrom the first surface 51 to the second surface 53. However, embodimentsare not limited to rib shaped structures. Furthermore, each of theplurality of interlocking segments 50A, 50B, 50C, and 50D includes afirst interlocking feature 55 configured to receive a secondinterlocking feature 54. For example, the first interlocking feature 55may be a flange having a receptacle for receiving the secondinterlocking feature 54. The first interlocking feature 55 and secondinterlocking feature 54 are positioned on different edges of each of theplurality of interlocking segments 50A, 50B, 50C, and 50D so that oneinterlocking segment 50A may be connected to another interlockingsegment 50B.

Each of the plurality of interlocking segments 50A, 50B, 50C, and 50Dfurther include a third interlocking feature 56 extending vertically(+Z-axis direction) from the first surface 51 of each of the pluralityof interlocking segments 50A, 50B, 50C, and 50D. The third interlockingfeatures 56 are configured to mate with a corresponding feature on theconductive target 40 thereby coupling the modular flexible layer 50 withthe conductive target 40. Similarly, each of the plurality ofinterlocking segments 50A, 50B, 50C, and 50D further include a fourthinterlocking feature 57 extending vertically (-Z-axis direction) fromthe second surface 53 of each of the plurality of interlocking segments50A, 50B, 50C, and 50D. The fourth interlocking features 57 areconfigured to mate with a corresponding feature on the upper housingstructure 10′ thereby coupling the modular flexible layer 50 with theupper housing structure 10′. The upper housing structure 10′ couples toa lower housing structure 12′ which function similar to the upper andlower structures 10 and 12 depicted and described with reference to FIG.6A.

Referring to FIG. 6F, a bottom perspective view of a connecting meansfor coupling two or more flexible tactile sensor modules 127A and 127Btogether is depicted. For example, in some embodiments the lowerstructure 12 may include receiving cavities 13 formed along the edges ofthe bottom surface of the lower structure 12. A receiving cavity 13 of afirst flexible tactile sensor module 127A may be configured to receive afirst end of a connecting member 14. Another receiving cavity 13 of asecond flexible tactile sensor module 127B may be configured to receivea second end of the connecting member 14. The connecting member 14 maycouple to the receiving cavities 13 through an interference or frictiontype connection. However, the coupling of two or more flexible tactilesensor modules 127A and 127B may not be limited to the specificembodiment described herein. Two or more flexible tactile sensor modules127A and 127B may be fastened to each other through any known fasteningmeans resulting in a rigid or flexible connection between the two ormore flexible tactile sensor modules 127A and 127B.

Referring now to FIG. 6G an illustrative diagram of a magnetic field ofa coil 25 interacting with a conductive target 40 is depicted. Whencurrent (e.g., alternating current AC) flows through the coil 25 an ACmagnetic field 26 is induced. The magnetic field 26 will induce eddycurrents 41 in nearby conductors such as a conductive target 40.

The eddy currents 41 are a function of the distance, size, andcomposition of the conductor. The eddy currents 41 generate their ownmagnetic field 42, which opposes the original field 26 generated by thecoil 25 (also referred to as the sensor inductor). By opposing theoriginal field 26, the original field 26 is weakened. This produces areduction in inductance compared to the inductor’s free spaceinductance. The interactions between these structures are phenomenaknown as inductive coupling. That is, the eddy currents 41 induced onthe conductive target 40 flow in such a way that they weaken themagnetic field 26 of the source coil 25 according to Lenz’s Law. As theconductive target 40 moves closer to the coil 25 the eddy currents 41increase, and the magnetic field 26 of the source coil 25 weakensfurther. When the inductance of the system is reduced, the resonantfrequency of the coil 25 increases.

Additional information regarding example flexible tactile sensors 127 isprovided in U.S. Pat. Appl. No. 17/344,354, which is hereby incorporatedby reference in its entirety.

It should be understood that embodiments are not limited by the flexibletactile sensors 127 illustrated by FIGS. 6A-6G, and that other sensorsmay be utilized.

Referring now to FIG. 7 , the array of flexible tactile sensors 127 maybe configured as an array of columns and rows. However, in otherembodiments the flexible tactile sensors 127 may be arranged in acircular array, an elliptical array, or an irregular array.

As shown in FIG. 7 , the array of flexible tactile sensors 127 may bearranged in an arcuate manner such that the body structure 120 has aconvex shape. In this manner, the body structure 120 may be shaped in asimilar manner as a person’s body core, such as a person’s chest.Referring now to FIG. 8 , the body structure 120 of the example robot100 includes an arcuate base 180 on which the array of flexible tactilesensors 127 are attached. FIG. 8 illustrates a rear surface of thearcuate base 180. The example arcuate base 180 includes two crossbarmembers 181 and a plurality of slats 183 that are coupled to the twocrossbar members 181 (e.g., by fasteners) to define an arcuate (i.e.,convex) surface on which the array of flexible tactile sensors isattached. Wiring 184 for connecting the individual flexible tactilesensors 127 to a processor of the robot 100 may be routed through theslats 183, for example. The crossbar members 181 can be changed out tomodify the curve of the chest. The illustrated configuration has aslight convex curve with the surface of each slat (and thus the base ofeach force/geometry sensor ) angled 170° from those horizontallyadjacent. This curve could be updated to have a more or less extremeangle between the slats, or to even be concave, in order to supportdifferent types of grasps.

Embodiments of the present disclosure may also provide for the abilityfor the body structure 120 to tilt backwards, much like a human doeswhen she leans backwards when supporting and carrying a large and/orheavy object. FIG. 9A illustrates a body structure 120 coupled to one ormore vertical rails 119 (which may be the same or different than thevertical rail 111 illustrated in FIG. 1 ). The one or more verticalrails 119 may pivotably coupled to one or more tilt structure supportmembers 126 at pivot point P₁. A tilt structure 124 is pivotably coupledto the one or more vertical rails 119 at pivot point P₂ and pivotablycoupled to the tilt structure support member 126 at pivot point P₃. Thetilt structure 124 is operable to tilt the body structure 120 in abackward direction away from a rail system defined by the one or morevertical rails 119 to support an object. The tilt structure 124 may beany component capable of tilting the one or more vertical rails 119(i.e., the rail system) and the body structure 120. Non-limitingexamples of components for the tilt structure 124 include a linearmotor, a hydraulic jack, and a pneumatic jack.

FIG. 9A illustrates the tilt structure 124 in an extended position suchthat the one or more vertical rails 119 are upright and an angle α₁between the one or more vertical rails 119 and the tilt structuresupport member 126 is about 90°. FIG. 9B illustrates the tilt structure124 in a retracted position such that the one or more vertical rails 119and thus the body structure 120 tilts back as indicated by arrow A, andan angle α₂ between the one or more vertical rails 119 and the tiltstructure support member 126 is less than angle α₁. Thus, the tiltstructure 124 may assist the robot 100 in supporting a large and/orheavy object.

Referring once again to FIG. 1 , the two arms 130 are adjacent to thebody structure 120. The arms 130 may have any number of segments and anynumber of actuatable joints. Each arms 130 further includes an endeffector 140, which in the illustrated embodiment is a soft bubblegripper configured for gripping an object by contact. The two arms 130are operable to wrap around an object, and press the object against thebody structure 120, much like a human would wrap her arms around anobject and press the object against her core (i.e., stomach and/orchest).

FIG. 10 illustrates an example robot 100 having its arms 130 wrappedaround a box 117 such that the box 117 is pressed against the bodystructure 120 (not visible in FIG. 10 ). The lift actuator 125 isoperable to lift the box 117 as well as lower the box 117 along thevertical rail 111. The tilt structure 124 is operable to tilt the box117 backwards to further support the hamper 117.

To perform the grasping of a large object, such as the hamper 117 shownin FIG. 10 , it may be desirable to provide tactile sensing on the arms130 of the robot 100 such that the robot may understand how it iscontacting and grasping the object by feedback. Referring once again toFIG. 1 , each arm 130 has a plurality of deformable sensors 150 disposedthereon. The deformable sensors 150 are also referred to as sensordevices herein. The deformable sensors 150 act as contact sensors thatsense contact between an object and the arm 130. The deformable sensor150 may generate a signal when contact is made against it. Any number ofdeformable sensors 150 may be provided on each arm. In the illustratedembodiment, each segment of the robot arms 130 has a deformable sensor150 around it.

Referring now to FIG. 11 , an example deformable sensor 150 isillustrated. The deformable sensor 150 generally comprises an inflatablediaphragm 155 having a port 156, a pressure sensor 153, and a tubing 157that fluidly couples the port 156 to the pressure sensor 153. Theinflatable diaphragm 155 may be made of a deformable material, such as,without limitation, polyvinyl chloride. The inflatable diaphragm 155 maybe configured as a ring that can be disposed around a segment of therobot arms 130. FIG. 12 shows how a deformable sensor 150 may bedisposed around a segment 192 of a robot arm 130.

Referring once again to FIG. 11 , the inflatable diaphragm 155 may alsoinclude an inflation port that is utilized to inflate the inflatablediaphragm 155 to the desired pressure. The pressure sensor 153 may bemaintained at a location separate from the inflatable diaphragm 155. Forexample, the pressure sensor 153 may be maintained within a body orother housing of the robot 100. Although the pressure sensor 153 isillustrated as being remote from the inflatable diaphragm, it should beunderstood that it may be provided within the inflatable diaphragm 155.In such embodiments, one or more signal wires may be provided to one orprocessors within the robot 100 to communicate a pressure reading.Alternatively, the pressure sensor may wireless communicate pressurereadings to the one or more processors within the robot 100.

The pressure sensor 153 is operable to detect a pressure within theinflatable diaphragm 155, and provides a scalar pressure value. Whencontact is made with inflatable diaphragm 155, the pressure increasesbecause the interior volume within the inflatable diaphragm 155decreases. When the pressure within the inflatable diaphragm 155 meets apredetermined criteria, contact with the deformable sensor 150 may beinferred. For example, when the pressure sensor 153 detects a pressureabove a predetermined threshold, a processor 158 or other component maygenerate a contact signal indicating contact with the deformable sensor150. As another example, when a pressure within the inflatable diaphragmas measured by the pressure sensor 153 changes by a threshold percentage(e.g., a 10% increase), a processor or other component may generate acontact signal indicating contact within the deformable sensor 150. Whenthe pressure within the inflatable diaphragm 155 does not meet apredetermined criteria, a processor or other component may not produce acontact signal. In this manner, the deformable sensor 150 may act as acontact sensor for the arms (and/or other components) of the robot 100.

Referring once again to FIG. 12 , a deformable sensor 150 is disposedaround a segment 192 of a robot arm 130. In some embodiments, thedeformable sensor 150 further comprises an outer cover layer 190disposed around the inflatable diaphragm 155. The outer cover layer 190has properties to protect the inflatable diaphragm 155 from being cut orpunctured by a sharp object, like a knife, that may be present inuncontrolled, cluttered environments. Thus, the outer cover layer 190should have a suitable strength to prevent the inflatable diaphragm 155from being cut or punctured. The outer cover layer 190 may cover boththe exterior surface of the inflatable diaphragm 155 as well as aninterior surface of the inflatable diaphragm 155 that faces the arm 130(or other robot component).

As non-limiting examples, the material may have a strength greater thanor equal to 30 cN/dtex, greater than or equal to 35 cN/dtex, greaterthan or equal to 40 cN/dtex, or greater than or equal to 45 cN/dtex. Asfurther non-limiting examples, the outer cover layer may be fabricatedfrom ultra-high molecular weight polyethylene or poly-paraphenyleneterephthalamide. As a further non-limiting example, the outer coverlayer 190 may be fabricated from Dyneema made by Royal DSM of TheNetherlands.

In some embodiments, a first material provides the high strength for theouter cover layer 190, and a second material is provided to provideanother function. For example, a high friction second material may bewoven with the first material to increase the coefficient of friction ofthe outer cover layer 190 with respect to an object. Thus, the secondmaterial has a coefficient of friction with respect to an object that isgreater than a coefficient of friction of the first material withrespect to the same object. Such a second material having a highcoefficient of friction may prevent the robot 100 from dropping anobject due to the object slipping against the outer cover layer 190 ofthe deformable sensor 150.

In some embodiments, the second material may be a conductive materialthat is woven with the first material, or a third material that isconductive is woven with the first material and the second material toprovide an additional functionality of capacitive sensing. Thus, theouter cover layer 190 may detect contact with an electrically conductiveobject, such as a metal object or a person’s hand.

It should be understood that the deformable sensors 150 described hereinmay be provided on any robot of any configuration, and are not limitedto being applied to the robot 100 illustrated in FIGS. 1-10 .

Although the deformable sensors 150 detect contact with an object, theyalone to not provide data relating to localized contact with thedeformable sensors 150. In other words, each deformable sensor 150 canonly detect whether or not contact with an object was made and not thespecific location on the deformable sensor 150 where contact was made.Thus, in some embodiments, additional sensors may be provided to providelocalized contact feedback regarding contact between the deformablesensors 150 and an object.

As a non-limiting example, an array of force sensors may be disposed onat least one of an inner surface of the inflatable diaphragm 155 (orouter cover layer 190, if provided) and an outer surface of theinflatable diaphragm 155 (or outer cover layer 190, if provided). As anon-limiting example, the array of force sensors may be disposed betweenthe outer cover layer 190 and the inflatable diaphragm 155. As describedin more detail below, the array of force sensors provides one or moresignals indicative of a location of contact between an object and thedeformable sensor 150.

Referring now to FIG. 13 , an example assembly 161 providing an array offorce sensors 165 is illustrated. The illustrated array of force sensors165 is configured as individual linear force sensors. As a non-limitingexample, each force sensor 165 may be configured as carbon-doped linearpotentiometers; however, other linear force sensors may be utilized.Each force sensor 165 provides a signal indicative of contact along itslength. Although the array of force sensors 165 are illustrated aslinear force sensors, it should be understood that individual, discreteforce sensors may be utilized. In the illustrated example, each forcesensor 165 has an electrical connector 167 for connecting to one or morewiring harnesses that provide respective contact signals to one or moreprocessors of the robot 100.

In some embodiments, a force concentrator 166 is disposed on a topsurface of each force sensor 165. The force concentrators 166 extend aheight above the top surface of the force sensors 165. The forceconcentrators 166 may be fabricated from any material. As a non-limitingexample, the force concentrators 166 may be fabricated from a rigidplastic or stiffened rubber. The force concentrators 166 increase theforce sensors 165 sensitivity to contact, particularly when the forcesensors 165 are disposed beneath the outer cover layer 190.

As shown in FIG. 13 , the assembly 161 further includes a sensor housing162 configured to receive the array of force sensors 165. The sensorhousing 162 is made of a pliable material so that it may be wrappedaround the robot arm 130 (or other robot component) or the inflatablediaphragm. The example sensor housing 162 includes two tabs 163 thathave a width w that is less than that of the sensor housing 162 thatreceives the array of force sensors 165. The reduces width w mayincrease the flexibility of the sensor housing 162. It should beunderstood that other embodiments may not include tabs 163 having areduced width.

In the illustrated embodiment, the sensor housing 162 includes securingfeatures 164 at each tab 163 that may be used to secure the sensorhousing 162 to the robot arm 130, the inflatable diaphragm 155, or theouter cover layer 190. The securing features 164 may be configured toreceive an elastic member (such as elastic rope, a rubber band, and/orthe like) to hold pull the two tabs 163 together to secure the sensorhousing 162 to the desired component. It should be understood that othermethods of securing the sensor housing 162 to the desired component maybe provided.

FIG. 14 illustrates the assembly 161 attached to an outer surface of anouter cover layer 190. However, in other embodiments the assembly 161may be disposed under an outer cover layer 190, or even disposed on arigid robot segment such that it is between the rigid robot segment andthe deformable sensor 150. FIG. 15 illustrates a robot arm 130 havingfour deformable sensors 150 with outer cover layers 190 on four rigidsegments 192 of the robot arm 130.

It should be understood that the assembly 161 having force sensors 165may be applied to any robot or machine, and are not limited to beingapplied to the robot 100 illustrated by FIGS. 1-10 .

In some cases, the deformable sensor 150 may undesirably slip up and/ordown the robot 130, as well as rotate around the robot arm 130. Thisslipping and/or rotation of the deformable sensor 150 may cause errorsin contact location signals, as well as may cause the robot 100 to dropan object. Thus, in some embodiments, structures may be provided on therigid segments 192 of the robot 100 to prevent movement of thedeformable sensor(s) 150. In other words, structures to limit movementof the deformable sensor(s) 150 may be positioned between the rigidsegment(s) 192 and the deformable sensors(s) 150.

Referring now to FIG. 16 , an example rigid segment 192 of a robothaving a member 196 for reducing the movement of a deformable sensor 150is illustrated. As shown in FIG. 16 , the member 196 is attached to therigid segment 192. The member 196 may be attached in any manner (e.g.,straps, fasteners, adhesive, and/or the like). In the illustratedembodiment, the member 196 is attached by a Velcro pad 195E. However,other means for attaching the member 196 may be utilized. FIG. 16illustrates additional Velcro pads 195A-195D for attaching additionalmembers (not shown) that prevent movement.

In some embodiments, the member(s) 196 is a compliant member. Forexample, the member(2) 196 may be made of a foam material thatcompresses upon contact with an object. A compliant member 196 may bemore suitable than a rigid member because a compliant member 196 willprovide more deformability, making for a softer robot 100.

The shape of the member 196 may be selected to conform to the particularrigid segment 192 to which it is attached. In the example of FIG. 16 ,the rigid segment 192 is tapered (i.e., it has a non-uniform thickness),which may lead to a member 196 also having a tapered shape to betteraccept the cylindrically shaped deformable sensor 150. For example, inthe smaller surface area of the rigid segment 192, the member 196 mayhave a larger surface area than in the larger area of the rigid segment192. The combination of the smaller portion of the rigid segment 192 andthe larger area of the member 196 provides for a cylindrical shapearound which the cylindrically shaped deformable sensor 150 is disposed.

Referring now to FIG. 17 , any number of members 196A-196E (e.g.,compliant members) may be disposed on an individual rigid segment 192 toprevent linear and/or rotational movement of a deformable sensor 150.Further, as shown in FIG. 17 , one or more of the members 196A-196E mayfurther comprise a friction tape 197A-197E to increase the coefficientof friction with respect to the deformable sensor 150 to further preventmovement. Thus, the members 196A-196E have a coefficient of frictionwith respect to the deformable sensor 150 that is greater than acoefficient of friction between the deformable sensor 150 and the rigidsurface 192. Any friction tape may be utilized. In other embodiments, ahigh friction coating may be applied to one or more of the members196A-196E in addition to, or instead of, friction tape. In yet otherembodiments, no additional high friction components may be provided.Rather, the material of the members 196A-196E has a high enoughcoefficient of friction with respect to the deformable sensor 150 toprevent movement.

The number and shape of the members may be provided on a member to matchan interior contour of a deformable sensor. FIG. 18 illustrates across-sectional view of the rigid segment 192 depicted in FIG. 17 . Theinflatable diaphragm 155 of the deformable sensor 150 may have “valleys”on the interior surface when fully inflated. These valleys are caused bya crease forming in the inflatable diaphragm upon inflation. In theembodiment of FIG. 18 , two semi-elliptically shaped members 196A and196D are on opposing surfaces of the rigid segment 192 and areconfigured to extend into the valleys of the interior surface of thedeformable sensor 150. Two relatively flat members 196B and 196C aredisposed on the other opposing surfaces of the rigid segment 192. Byextending the semi-elliptically shaped members 196A, 196D into thevalleys of the deformable sensor 150, rotational movement of thedeformable sensor 150 with respect to the rigid segment 192 may beprevented.

FIG. 19 illustrates another embodiment of a rigid segment 301 havingconcave surfaces 302 in cross-section. Compliant member 303 arepositioned within the concave surfaces 302 to provide a cylindricalshape in cross-section over which a deformable sensor 150 may bedisposed.

It should be understood that the members for preventing deformablesensor movement may be applied to any robot or machine, and are notlimited to being applied to the robot 100 illustrated by FIGS. 1-10 .

Contact sensors other than the deformable sensors 150 described abovemay also be applied to the robot. Referring now to FIG. 20 , an examplepressure sensor device 400 that may be applied to a robot or othermachine is illustrated. The pressure sensor device 400 may be providedto detect contact between an object and a robot, such as the robot 100illustrated by FIGS. 1-10 , for example.

The example pressure sensor device 400 illustrated by FIG. 20 comprisesa base layer 402 and a deformable layer 404 bonded to the base layer 402such that the base layer 402 and the deformable layer 404 define atleast one inflatable chamber 403. In some embodiments, the deformablelayer 404 may be bonded to the base layer 402 at their interfaces. Forexample, the deformable layer 404 may be heat sealed to the base layer402 by a heat sealer such that the deformable layer 404 is bonded to thebase layer 402 with no intermediate material (i.e., adhesive).

The base layer 402 may be fabricated with a rigid material, such as athermoplastic. The deformable layer 404 is fabricated from a compliantmaterial to enable deformation when in contact with an object. As anon-limiting example, the deformable layer 404 may be made from athermoplastic polyurethane. The two materials for the base layer 402 andthe deformable layer 404 may be chosen such that they may be bondedtogether by heat sealing, for example.

The pressure sensor device 400 further includes a pressure sensor (notshown in FIG. 20 and which may be similar to the pressure sensor 153described above) that is operable to send a signal indicative ofpressure within the inflatable chamber 403, which may be inflated with agas or a fluid. In some embodiments, the pressure sensor may be disposedwithin the inflatable chamber 403 and communicate with a centralprocessor of the robot by a wired or wireless communication method. Inother embodiments, the pressure sensor is remote from the inflatablechamber 403. As shown in FIG. 20 , the pressure sensor device 400 mayinclude a port 406 that may be used for both inflating the inflatablechamber 403 as well as for connecting to a fitting 408 that is furtherfluidly coupled to tubing 410. The tubing 410 may also be fluidlycoupled to a remote pressure sensor so that the pressure sensor isfluidly coupled to the inflatable chamber 403. As shown in FIG. 20 , asecond fitting 412 may be fluidly coupled to the tubing 410 to fluidlycouple the tubing 410 to the pressure sensor.

Embodiments are not limited to embodiments where the base layer is arigid material. In some embodiments, both the base layer and thedeformable layer are deformable and/or compliant. In some embodiments,both the base layer and the deformable layer are fabricated from thesame material.

Referring to FIGS. 21A and 21B, another example pressure sensor device450 is illustrated. FIG. 21A shows the base layer 452 while FIG. 21Bshows the deformable layer 454 that is configured to contact an object.It should be understood that the base layer 452 and the deformable layer454 may be made of the same materials or different materials. Thematerial(s) of the base layer 452 and the deformable layer 454 may besuch that that the base layer 452 and the deformable layer 454 are heatsealed to form a sealed perimeter 458 around an inflatable chamber 453.As shown in FIG. 21A, the base layer 452 may have a port 456 that isused to both inflate the inflatable chamber 453 as well as fluidlycouple the inflatable chamber 453 to a pressure sensor (not shown) bytubing 460.

Any number of inflatable chambers 453 may be fabricated from a singlebase layer 452 and a single deformable layer 454. For example, an arrayof inflatable chambers 453 may be formed by heat sealing. FIG. 24 ,which is described in more detail below, illustrates an example array ofinflatable chambers in a single base layer and a single deformablelayer. The plurality of inflatable chambers 453 may be arranged in anarray, or may be arbitrarily arranged. Each inflatable chamber 453 hasassociated therewith a pressure sensor. In this manner, the plurality ofinflatable chambers 453 can provide localized contact feedback regardingan object contacting the robot.

FIGS. 22A-22C illustrate another example pressure sensor device 470.FIGS. 22A and 22B illustrate a bottom surface of a base layer 472 thatis fabricated from a thermoplastic resin. As a non-limiting example, thethermoplastic resin may be Worbla® sold by Cast4Art of Neuhemsbach,Germany. Worbla® may be advantageous because it is capable of beingshaped/molded into a desirable shape and can also be heat-sealed toother materials, such as the deformable layer 474 (FIG. 22C). Forexample, the thermoplastic resin, such as Worbla®, may be shaped to thecontours of the rigid segment of the robot to which it is attached.

As shown in FIG. 22A, the base layer 472 has a port 476 that isconfigured as a through-hole. The port 476 is then provided with afitting 479 to be coupled to a tubing 410 that is used to both inflatean inflatable chamber 473 and fluidly couple the inflatable chamber 473to a pressure sensor (not shown, but see pressure sensor 153 of FIG. 11).

FIG. 22C shows the inflatable chamber 473, which is defined by the baselayer 472 (e.g., Worbla® or some other thermoplastic resin) and adeformable layer 474 that is fabricated from a thermoplasticpolyurethane. The base layer 472 and the deformable layer 474 are bonded(e.g., heat sealed) around a perimeter 478 to define the inflatablechamber 473, which is filled with a gas or fluid.

The shape of the pressure sensor devices described herein are notlimited to dome-shaped inflatable chambers. The pressure sensor devicesdescribed herein may take on any shape. Referring to FIG. 23 , apressure sensing device 490 having an inflatable chamber 493 shaped as acube is illustrated. The inflatable chamber 493 is defined by cutswithin a deformable layer that are made to form the cubic shape. Itshould be understood that other shapes are also possible.

It should be understood that the pressure sensor devices describedherein may be provided on robots and/or machines other than the robot100 illustrated by FIGS. 1-10 .

As stated above, a sheet of a base layer and a deformable layer having aplurality of inflatable chambers may be used as a soft robot “skin”capable of detecting the location of contact of a robot. The skinprovides both softness to the robot as well as the sense of touch. FIG.24 illustrates an example array 500 of pressure sensor devices definedby inflatable chambers 503 that is disposed around a rigid segment 592of a robot. The rigid segment 592 has a hollow inner chamber 555 tomaintain the tubing for the individual inflatable chambers 503.Additionally, a plurality of pressure sensors (not shown) may bedisposed within the inner chamber 444. The array 500 of pressure sensordevices provides a soft skin to the robot as well as provides feedbackregarding contact between an object and the robot.

In some embodiments, both the rigid segment and the array of pressuresensor devices have features that enable the array of pressure sensordevices (i.e., the robot “skin”) to be attached to the rigid segment.Referring now to FIG. 25 , two rigid segments 690A, 690B (also referredto herein as structures) provided on a robot arm 630 for receiving robotskins having arrays of pressure sensor devices are illustrated. Eachrigid segment 690A, 690B a first set of engagement features 697A, 697Bthat extend from an outer surface of the rigid segment 690A, 690B at afirst location 698A, 698B. Although not shown in FIG. 25 , each rigidsegment 690A, 690B further has a second set of engagement features thatextend from the outer surface at a second location. The first location698A, 698B is offset from the second location on each rigid segment690A, 690B. In the illustrated embodiment, the first sets of engagementfeatures 697A, 697B and the second sets of engagement features areconfigured as hooks operable to receive corresponding engagementfeatures of a robot skin.

Referring now to FIG. 26 , a first sensor assembly 550A (i.e., firstarray of pressure sensor devices) is shown attached to the first rigidsegment 690A and a second sensor assembly 550B (i.e., a second array ofpressure sensor devices) is shown attached to the second rigid segment690B. Referring specifically to the first sensor assembly 550A, itincludes a first member 559 proximate to a first edge 557 of the firstsensor assembly 550A, and a second member 559′ proximate to a secondedge 557′ of the first sensor assembly 550A. The first member 559 andthe second member 559′ are rigid and configured to be disposed in thefirst and second sets of engagement features 697A, 697A′ of the firstrigid segment 690A, respectively. As a non-limiting example, the firstand second members 559, 559′ are configured as metal rods. However, itshould be understood that other rigid materials are also possible.

To attach the first sensor assembly 690A to the first rigid segment690A, the first member 559 is disposed within the hooks as defined bythe first set of engagement features 697A (FIG. 25 ) at the firstlocation 698A. The first sensor assembly 690A is then pulled taut sothat it is under tension. The second member 559′ is then disposed withinthe hooks defined by the second set of engagement features at the secondlocation 698′. The tension on the first sensor assembly 690A then holdsthe first sensor assembly 690A in an engagement state with the firstrigid segment 690A.

It should now be understood that embodiments of the present disclosureare directed to robots and various assorted components that enable arobot to lift heavy objects with its arms and chest, as we as to softand deformable contact sensors that provide feedback regarding objectcontact location.

In a first aspect, a robot includes a rail system, a body structurecoupled to the rail system, a first arm coupled to a first side of thebody structure, one or more first arm actuators providing the first armwith multiple degrees of freedom, a second arm coupled to a second sideof the body structure, one or more second arm actuators providing thesecond arm with multiple degrees of freedom, a lift actuator operable tomove the body structure along the rail system, and a tilt structurecoupled to the body structure. The one or more first arm actuators andthe one or more second arm actuators are operable to wrap the first armand the second arm around an object and hold the object against the bodystructure. The tilt structure is operable to tilt the body structure ina direction away from the rail system to support the object. The liftactuator is operable to move the body structure such that the object islifted on the rail system.

In a second aspect, a robot according to the first aspect, furtherincluding a tilt structure support member, wherein the tilt structure iscoupled to the tilt structure support member at a first end and the tiltstructure is coupled to a rear surface of the body structure at a secondend such that the tilt structure defines an angle with respect to thetilt structure support member.

In a third aspect, a robot according to the second aspect, wherein thetilt structure comprises a pneumatic jack.

In a fourth aspect, a robot according to the second or third aspect,wherein the tilt structure is controlled such that a tilt angle of thebody structure with respect to the tilt structure support member isbased at least in part on a weight of the object.

In a fifth aspect, a robot according to any preceding aspect, whereinthe body structure comprises one or more force sensors operable todetect a force applied to the body structure.

In a sixth aspect, a robot according to the fifth aspect, wherein theone or more force sensors comprises an array of flexible tactilesensors.

In a seventh aspect, a robot according to the sixth aspect, wherein eachforce sensor of the array of flexible tactile sensors is operable todetect a force magnitude and a force direction.

In an eighth aspect, a robot according to the seventh aspect, whereineach force sensor comprises a compliant layer.

In a ninth aspect, a robot according to the seventh or eighth aspect,further including a processor, wherein the processor is operable toreceive one or more and, from the one or more signals, determine ageometry of the object.

In a tenth aspect, a robot according to any one of the fifth throughninth aspects, further including a friction material that covers the oneor more force sensors.

In an eleventh aspect, a robot according to any preceding aspect,further including one or more compliant sensors positioned on at leastone of the first arm and the second arm.

In a twelfth aspect, a robot according to the eleventh aspect, whereinthe one or more compliant sensors comprises a deformable membrane.

In a thirteenth aspect, a robot according to any preceding aspect,further including one or more control members operable to be grasped bya user such that the user may move the robot.

In a fourteenth aspect, a robot includes a rail system, a body structurecoupled to the rail system, the body structure having one or more forcesensors operable to detect a force applied to the body structure, afirst arm coupled to a first side of the body structure, a plurality offirst arm actuators providing the first arm with multiple degrees offreedom, a second arm coupled to a second side of the body structure, aplurality of second arm actuators providing the second arm with multipledegrees of freedom, a lift actuator operable to move the body structurealong the rail system, and a tilt structure coupled to the bodystructure. The plurality of first arm actuators and the plurality ofsecond arm actuators are operable to wrap the first arm and the secondarm around an object and hold the object against the body structure. Thetilt structure is operable to tilt the body structure in a directionaway from the rail system to support the object. The lift actuator isoperable to move the body structure such that the object is lifted onthe rail system.

In a fifteenth aspect, a robot according to the fourteenth aspect,further including a tilt structure support member, wherein the tiltstructure is coupled to the tilt structure support member at a first endand the tilt structure is coupled to a rear surface of the bodystructure at a second end such that the tilt structure defines an anglewith respect to the tilt structure support member.

In a sixteenth aspect, a robot according to the fifteenth aspect,wherein the tilt structure is a pneumatic jack.

In a seventeenth aspect, a robot according to the fifteenth aspect orthe fourteenth aspect, wherein the tilt structure is controlled suchthat a tilt angle of the body structure with respect to the tiltstructure support member is based at least in part on a weight of theobject.

In an eighteenth aspect, a robot according to any one of the fourteenththrough seventeenth aspects, wherein the one or more force sensorscomprises an array of flexible tactile sensors.

In a nineteenth aspect, a robot according to the eighteenth aspect,wherein each force sensor of the array of flexible tactile sensors isoperable to detect a force magnitude and a force direction.

In a twentieth aspect, a robot according to the nineteenth aspect,wherein each force sensor comprises a compliant layer.

In a twenty-first aspect, a sensor assembly includes a compliantsubstrate assembly having a base layer, and a deformable layerheat-sealed to the base layer such that the base layer and thedeformable layer define at least one inflatable chamber. The sensorassembly further includes a first member proximate to a first edge ofthe compliant substrate assembly, a second member proximate to a secondedge of the compliant substrate assembly, wherein the second edge isopposite the first edge, and at least one pressure sensor fluidlycoupled to the at least one inflatable chamber and operable to produce asignal indicative of a pressure within the at least one inflatablechamber.

In a twenty-second aspect, a sensor assembly according to thetwenty-first aspect, wherein the at least one inflatable chamber isoperable to be filled with a gas.

In a twenty-third aspect, a sensor assembly according to thetwenty-second aspect, further including a tubing that fluidly couplesthe at least one inflatable chamber to the at least one pressure sensor.

In a twenty-fourth aspect, a sensor assembly according to any one of thetwenty-first through twenty-third aspect, wherein the base layer isfabricated from a first material and the deformable layer is fabricatedfrom a second material that is different from the first material.

In a twenty-fifth aspect, a sensor assembly according to any one of thetwenty-first through twenty-third aspects, wherein the at least oneinflatable chamber comprises an array of inflatable chambers.

In a twenty-sixth aspect, a sensor assembly according to thetwenty-fifth aspect, wherein the at least one pressure sensor comprisesa plurality of pressure sensors fluidly coupled to the array ofinflatable chambers.

In a twenty-seventh aspect, a sensor assembly according to any one ofthe twenty-first through twenty-sixth aspects, wherein the first memberand the second member are rods.

In a twenty-eighth aspect, a structure for receiving a compliantsubstrate assembly includes an outer surface, a first set of engagementfeatures extending from a first location of the outer surface, whereinthe first set of engagement features are configured to receive a firstmember of the compliant substrate assembly, and a second set ofengagement features extending from a second location of the outersurface that is offset from the first location by a distance, whereinthe second set of engagement features are configured to receive a secondmember of the compliant substrate assembly.

In a twenty-ninth aspect, a structure according to the twenty-eighthaspect, wherein the distance is greater than a length of the compliantsubstrate assembly as measured from the first member to the secondmember.

In thirtieth aspect, a structure according to the twenty-eighth aspector the twenty-ninth aspect, wherein the first set of engagement featurescomprises two or more first hooks and the second set of engagementfeatures comprises two or more second hooks.

In a thirty first aspect, a structure according to any one of the twentyeighth through thirtieth aspects, wherein the structure is at least aportion of a robot arm.

In a thirty second aspect, a sensor assembly includes a base structureincluding an outer surface, a first set of engagement features extendingfrom a first location of the outer surface, and a second set ofengagement features extending from a second location of the outersurface that is offset from the first location by a distance. The sensorassembly further includes a compliant substrate assembly including abase layer, a deformable layer heat-sealed to the base layer such thatthe base layer and the deformable layer define at least one inflatablechamber, a first member proximate to a first edge of the compliantsubstrate assembly, wherein the first member is held by the first set ofengagement features, and a second member proximate to a second edge ofthe compliant substrate assembly, wherein the second edge is oppositethe first edge and the second member is held by the second set ofengagement features such that the compliant substrate assembly isstretched over at least a portion of the base structure. The sensorassembly further includes at least one pressure sensor fluidly coupledto the at least one inflatable chamber and operable to produce a signalindicative of a pressure within the at least one inflatable chamber.

In a thirty third aspect, a sensor assembly according to the thirtysecond aspect, wherein the at least one inflatable chamber is operableto be filled with a gas.

In a thirty fourth aspect, a sensor assembly according to the thirtythird aspect, further including a tubing that fluidly couples the atleast one inflatable chamber to the at least one pressure sensor.

In a thirty fifth aspect, a sensor assembly according to any one of thethirty second through thirty fourth aspects, wherein the base layer isfabricated from a first material and the deformable layer is fabricatedfrom a second material that is different from the first material.

In a thirty-sixth aspect, a sensor assembly according to any one of thethirty second through thirty fifth aspects, wherein the at least oneinflatable chamber comprises an array of inflatable chambers.

In a thirty seventh aspect, a sensor assembly according to thethirty-sixth aspect, wherein the at least one pressure sensor comprisesa plurality of pressure sensors fluidly coupled to the array ofinflatable chambers.

The thirty eighth aspect, a sensor assembly according to any one of thethirty second through thirty seventh aspects, wherein the first memberand the second member are rods.

In the thirty ninth aspect, a sensor assembly according to any one ofthe thirty second through thirty eighth aspects, wherein the distance isgreater than a length of the compliant substrate assembly as measuredfrom the first member to the second member.

In a fortieth aspect, a sensor assembly according to any one of thethirty second through thirty ninth aspects, wherein the first set ofengagement features comprises two or more first hooks and the second setof engagement features comprises two or more second hooks.

In a forty first aspect, a pressure sensor device includes a base layer,a deformable layer bonded to the base layer such that the base layer andthe deformable layer define at least one inflatable chamber, and atleast one pressure sensor fluidly coupled to the at least one inflatablechamber and operable to produce a signal indicative of a pressure withinthe at least one inflatable chamber.

In forty second aspect, the pressure sensor according to the forty firstaspect, wherein the at least one inflatable chamber is operable to befilled with a gas.

In a forty third aspect, a pressure sensor according to the forty secondaspect, further including a tubing that fluidly couples the at least oneinflatable chamber to the at least one pressure sensor.

In a forty fourth aspect, a pressure sensor according to any one of theforty first through forty third aspects, wherein the deformable layerdefines a dome shape when the at least one inflatable chamber is filledwith a gas.

In a forty fifth aspect, a pressure sensor according to any one of theforty first through forty fourth aspects, wherein the deformable layerdefines a cubic shape when the at least one inflatable chamber is filledwith a gas.

In a forty sixth aspect, a pressure sensor according to any one of theforty first 340 fifth aspects, wherein the base layer is fabricated froma first material and the deformable layer is fabricated from a secondmaterial that is different from the first material.

In a forty seventh aspect, a pressure sensor according to the fortysixth aspect, wherein the first material is a thermoplastic resin andthe second material is a thermoplastic polyurethane material.

In a forty eighth aspect, a pressure sensor according to the forty-sixaspect or the forty seventh aspect, wherein the first material is anacrylic material and the second material is a thermoplastic polyurethanematerial.

In a forty ninth aspect, a pressure sensor according to one of the fortyfirst through forty eighth aspects, wherein the at least one inflatablechamber comprises an array of inflatable chambers.

In a fiftieth aspect, a pressure sensor according to the forty ninthaspect, wherein the at least one pressure sensor comprises a pluralityof pressure sensors fluidly coupled to the array of inflatable chambers.

In a fiftieth first aspect, a robot includes a component having asurface and a pressure sensor device coupled to the surface, thepressure sensor device including a base layer, a deformable layer bondedto the base layer such that the base layer and the deformable layerdefine at least one inflatable chamber, and at least one pressure sensorfluidly coupled to the at least one inflatable chamber and operable toproduce a signal indicative of a pressure within the at least oneinflatable chamber.

In a fifty second aspect, a robot according to the fifty first aspect,wherein the surface includes an arm.

In a fifty third aspect, a robot according to any one of the fifty firstor fifty second aspects, further comprising a tubing that fluidlycouples the at least one inflatable chamber to the at least one pressuresensor.

In a fifty fourth aspect, a robot according to any one of the fiftyfirst through fifty third aspects, wherein the deformable layer definesa dome shape when the at least one inflatable chamber is filled with agas.

In the fifty fifth aspect, a robot according to any one of the fiftyfirst through fifty third aspects, wherein the deformable layer definesa cubic shape when the at least one inflatable chamber is filled with agas.

In a fifty sixth aspect, a robot according to any one of the fifty firstthrough fifty fifth aspects, wherein the base layer is fabricated from afirst material and the deformable layer is fabricated from a secondmaterial that is different from the first material.

In a fifty seventh aspect, a robot according to the fifty sixth aspect,wherein the first material is a thermoplastic resin and the secondmaterial is a thermoplastic polyurethane material.

In a fifty eighth aspect, a robot according to the fifty sixth aspect,wherein the first material is an acrylic material and the secondmaterial is a thermoplastic polyurethane material.

In a fifty ninth aspect, a robot according to any one of the fifty firstthrough fifty eighth aspects, wherein the at least one inflatablechamber comprises an array of inflatable chambers.

In a sixtieth aspect, a robot according to the fifty ninth aspect,wherein the at least one pressure sensor comprises a plurality ofpressure sensors fluidly coupled to the array of inflatable chambers.

In a sixty first aspect, a robot includes a rail system extending in asystem direction, a body structure coupled to the rail system, the bodystructure comprising an array of flexible tactile sensors, wherein eachflexible tactile sensor of the array of flexible tactile sensors isoperable to produce a signal determinative of a magnitude and adirection of a force applied to the flexible tactile sensor, and a liftactuator operable to move the body structure along the rail system.

In a sixty second aspect, robot according to the sixty first aspect,further including a processor, wherein the processor is operable toreceive one or more signals from the array of flexible tactile sensorsand, from the one or more signals, determine a geometry of an objectpressed against the array of flexible tactile sensors.

In a sixty third aspect, a robot according to the sixty first or sixtysecond aspect, further including a friction material that covers thearray of flexible tactile sensors.

In a sixty fourth aspect, a robot according to any one of the sixtyfirst through sixty third aspects, wherein the body structure furthercomprises an arcuate base and the array of flexible tactile sensors arecoupled to the arcuate base.

In a sixty fifth aspect, a robot according to any one of the sixty firstthrough the sixty fourth aspects, wherein each tactile sensor of thearray of flexible tactile sensors includes a conductive targetpositioned in a first plane, at least three coils forming an arraywithin a second plane, the second plane spaced apart from the firstplane, a pliable material disposed between the conductive target and theat least three coils, and an electronic device electrically coupled toeach of the at least three coils, the electronic device configured toinduce an AC signal within each of the at least three coils and measurea change in inductance in the at least three coils in response tomovement of the conductive target.

In a sixty sixth aspect, a robot according to any one of the sixty firstthrough sixty fifth aspects, further including a first arm coupled to afirst side of the body structure, one or more first arm actuatorsproviding the first arm with multiple degrees of freedom, a second armcoupled to a second side of the body structure, and one or more secondarm actuators providing the second arm with multiple degrees of freedom,wherein the one or more first arm actuators and the one or more secondarm actuators are operable to wrap the first arm and the second armaround an object and hold the object against the body structure.

In a sixty-seventh aspect, a robot according to the sixty sixth aspect,wherein each of the one or more first arm actuators and the one or moresecond arm actuators includes a shoulder actuator that couples the firstarm and the second arm to the body structure, an elbow actuator, and awrist actuator.

In a sixtieth aspect, a robot according to the sixty sixth aspect,further including one or more deformable sensors positioned on at leastone of the first arm and the second arm.

In a sixty ninth aspect, a robot according to the sixty eighth aspect,wherein the one or more deformable sensors comprises a deformablemembrane.

In a seventieth aspect, a robot according to any one of the sixty firstthrough sixty ninth aspects, further including a tilt structure coupledto the body structure, wherein the tilt structure is operable to tiltthe body structure in a direction away from the rail system to supportan object.

In a seventy first aspect, a robot includes a rail system extending in asystem direction and a body structure coupled to the rail system, thebody structure comprising an array of flexible tactile sensors. Eachflexible tactile sensor of the array of flexible tactile sensors includea conductive target positioned in a first plane, at least three coilsforming an array within a second plane, the second plane spaced apartfrom the first plane, a pliable material disposed between the conductivetarget and the at least three coils, and an electronic deviceelectrically coupled to each of the at least three coils, the electronicdevice configured to induce an AC signal within each of the at leastthree coils and measure a change in inductance in the at least threecoils in response to movement of the conductive target. The robotfurther includes a first arm coupled to a first side of the bodystructure, a second arm coupled to a second side of the body structure,and a lift actuator operable to move the body structure along the railsystem.

In a seventy second aspect, a robot according to the seventy firstaspect, further including a processor, wherein the processor is operableto receive one or more signals from the array of flexible tactilesensors and, from the one or more signals, determine a geometry of anobject pressed against the array of flexible tactile sensors.

In a seventy third aspect, a robot according to the seventy first aspector the seventy second aspect, further including a friction material thatcovers the array of flexible tactile sensors.

In a seventy fourth aspect, a robot according to any one of the seventyfirst through seventy third aspects, wherein the body structure furthercomprises an arcuate base and the array of flexible tactile sensors arecoupled to the arcuate base.

In a seventy fifth aspect, a robot according to any one of the seventyfirst through seventy fourth aspects, further including one or morefirst arm actuators providing the first arm with multiple degrees offreedom, and one or more second arm actuators providing the second armwith multiple degrees of freedom. The one or more first arm actuatorsand the one or more second arm actuators are operable to wrap the firstarm and the second arm around an object and hold the object against thebody structure.

In a seventy-six aspect, a robot according to the seventy fifth aspect,wherein each of the one or more first arm actuators and the one or moresecond arm actuators includes a shoulder actuator that couples the firstarm and the second arm to the body structure, an elbow actuator, and awrist actuator.

In a seventy seventh aspect, a robot according to any one of the seventyfirst through seventy sixth aspects, further including a tilt structurecoupled to the body structure, wherein the tilt structure is operable totilt the body structure in a direction away from the rail system tosupport an object.

In a seventy eighth aspect, a robot according to any one of the seventyfirst through seventy seventh aspects, further including one or moredeformable sensors positioned on at least one of the first arm and thesecond arm.

In a seventy ninth aspect, a robot according to the seventy eighthaspect, wherein the one or more deformable sensors comprises adeformable membrane.

In an eightieth aspect, a robot according to any one of the seventyfirst through seventy ninth aspects, further including one or moredeformable sensors positioned on at least one of the first arm and thesecond arm.

In an eighty first aspect, a sensor device includes an inflatablediaphragm operable to be disposed on a member, and an array of forcesensors disposed about the inflatable diaphragm, wherein the array offorce sensors provides one or more signals indicative of a location ofcontact between an object and the inflatable diaphragm.

In an eighty second aspect, a sensor device according to the eightyfirst aspect, wherein the array of force sensors are operable to bedisposed on a surface of the member such that the array of force sensorscontacts the inner surface of the inflatable diaphragm.

In an eighty third aspect, a sensor device according to the eighty firstaspect or the eighty second aspect, further including a sensor housing,wherein the array of force sensors is disposed within the sensorhousing.

In an eighty fourth aspect, a sensor device according to any one of theeighty first through eighty third aspects, wherein the array of forcesensors comprises a plurality of linear force resistors.

In an eighty fifth aspect, a sensor device according to the eightyfourth aspect, wherein each linear force resistor comprises acarbon-doped linear potentiometer.

In an eighty sixth aspect, a sensor device according to any one of theeighty first through eighty fifth aspects, wherein the array of forcesensors comprises a plurality of individual force sensors.

In an eighty seventh aspect, a sensor device according to any one of theeighty first through eighty sixth aspects, wherein one or more forcesensors of the array of force sensors comprises a force concentrator.

In the eighty eighth aspect, a sensor device according to any one of theeighty first through eighty seventh aspects, wherein the inflatablediaphragm further includes a port, and the sensor device furtherincludes a pressure sensor and tubing, wherein the tubing fluidlycouples the port to the pressure sensor.

In an eighty ninth aspect, a sensor device according to any one of theeighty first through eighty eighth aspects, further including an outercover layer disposed around the inflatable diaphragm, wherein the outercover layer is fabricated from a material having a strength of greaterthan or equal to 35 cN/dtex.

In a ninetieth aspect, a sensor device according to the eighty ninthaspect, wherein the outer cover layer further includes one or moreadditional materials comprising one or more of an electricallyconductive material and a friction material having a coefficient offriction that is greater than a coefficient of friction of the material.

In a ninety first aspect, a robot includes at least one member, and asensor device including an inflatable diaphragm disposed on the at leastone member and an array of force sensors disposed about the inflatablediaphragm, wherein the array of force sensors provides one or moresignals indicative of a location of contact between an object and theinflatable diaphragm.

In a ninety second aspect, a robot according to the ninety first aspect,wherein the array of force sensors are disposed on a surface of the atleast one member such that the array of force sensors contacts the innersurface of the inflatable diaphragm.

In a ninety third aspect, a robot according to the ninety first aspector the ninety second aspect, wherein the sensor device further includesa sensor housing, wherein the array of force sensors is disposed withinthe sensor housing.

In the ninety fourth aspect, a robot according to any one of the ninetyfirst through ninety third aspects, wherein the array of force sensorsincludes a plurality of linear force resistors.

In a ninety fifth aspect, a robot according to the ninety fourth aspect,wherein each linear force resistor comprises a carbon-doped linearpotentiometer.

In a ninety sixth aspect, a robot according to any one of the ninetyfirst through ninety fifth aspects, wherein the array of force sensorsincludes a plurality of individual force sensors.

In a ninety seventh aspect, a robot according to any one of the ninetyfirst through ninety-sixth aspects, wherein one or more force sensors ofthe array of force sensors includes a force concentrator.

In a ninety eighth aspect, a robot according to any one of the ninetyfirst through ninety seventh aspects, wherein the inflatable diaphragmfurther includes a port, and the sensor device further includes apressure sensor and tubing, wherein the tubing fluidly couples the portto the pressure sensor.

In a ninety ninth aspect, a robot according to any one of the ninetyfirst through ninety eighth aspects, further including an outer coverlayer disposed around the inflatable diaphragm, wherein the outer coverlayer is fabricated from a material having a strength of greater than orequal to 35 cN/dtex.

In a one hundredth aspect, a robot according to any one of the ninetyfirst through ninety ninth aspects, further including one or morecompliant members disposed between a surface of the at least one memberand the inflatable diaphragm.

In a one hundred and first aspect, a sensor includes an inflatablediaphragm operable to be disposed on a member, wherein the inflatablediaphragm includes a port. The sensor further includes an outer coverlayer disposed around the inflatable diaphragm, wherein the outer coverlayer is fabricated from a material having a strength of greater than orequal to 35 cN/dtex, and a pressure sensor fluidly coupled to the portand operable to detect a pressure within the inflatable diaphragm.

In a one hundred and second aspect, a sensor according to the onehundred and first aspect, wherein the material of the outer cover layeris ultra-high molecular weight polyethylene.

In a one hundred and third aspect, a sensor according to the one hundredand first aspect or the one hundred and second aspect, wherein thematerial of the outer cover layer is poly-paraphenylene terephthalamide.

In a one hundred and fourth aspect, a sensor according to its any one ofthe one hundred and first through one hundred and third aspects, whereinthe outer cover layer is further fabricated from a second materialhaving a coefficient of friction that is greater than a coefficient offriction of the material.

In a one hundred and fifth aspect, a sensor according to the one hundredand fourth aspect, wherein the material and the second material arewoven to fabricate the outer cover layer.

In a one hundred and sixth aspect, a sensor according to any one of theone hundred and first through one hundred and fifth aspects, wherein theouter cover layer is further fabricated from a second material that iselectrically conductive.

In a one hundred and seventh aspect, a sensor according to any one ofthe one hundred and first through one hundred and sixth aspects, furtherincluding tubing that fluidly couples the pressure sensor to the port.

In a one hundred and eighth aspect, a robot component including a memberand one or more deformable sensors including an inflatable diaphragmdisposed on the member, the inflatable diaphragm comprising a port, anouter cover layer disposed around the inflatable diaphragm, wherein theouter cover layer is fabricated from a material having a strength ofgreater than or equal to 35 cN/dtex, and a pressure sensor fluidlycoupled to the port and operable to detect a pressure within theinflatable diaphragm.

In a one hundred and ninth aspect, a robot according to the one hundredand eighth aspect, wherein the material of the outer cover layer isultra-high molecular weight polyethylene.

In a one hundred and tenth aspect, a robot according to the one hundredand eighth aspect, wherein the material of the outer cover layer ispoly-paraphenylene terephthalamide.

In a one hundred and eleventh aspect, a robot according to the onehundred and eighth aspect, wherein the outer cover layer is furtherfabricated from a second material having a coefficient of friction thatis greater than a coefficient of friction of the material.

In a one hundred and twelfth aspect, a robot according to the onehundred and eleventh aspect, wherein the material and the secondmaterial are woven to fabricate the outer cover layer.

In a one hundred and thirteenth aspect, a robot according to any one ofthe one hundred and eighth through one hundred and twelfth aspects,wherein the outer cover layer is further fabricated from a secondmaterial that is electrically conductive.

In a one hundred and fourteenth aspect, a robot according to any one ofthe one hundred and eighth through one hundred and thirteenth aspects,wherein the member comprises a robot arm.

In a one hundred and fifteenth aspect, a robot including a rail system,a body structure coupled to the rail system, a first arm coupled to afirst side of the body structure, one or more first arm actuatorsproviding the first arm with multiple degrees of freedom, a second armcoupled to a second side of the body structure, one or more second armactuators providing the second arm with multiple degrees of freedom, oneor more deformable sensors disposed on one or more of the first arm andthe second arm. The one or more deformable sensors includes aninflatable diaphragm having a port, an outer cover layer disposed aroundthe inflatable diaphragm, wherein the outer cover layer is fabricatedfrom a material having a strength of greater than or equal to 35cN/dtex, and a pressure sensor fluidly coupled to the port and operableto detect a pressure within the inflatable diaphragm. The robot furtherincludes a lift actuator operable to move the body structure along therail system. The one or more first arm actuators and the one or moresecond arm actuators are operable to wrap the first arm and the secondarm around an object and hold the object against the body structure. Thelift actuator is operable to move the body structure such that theobject is lifted on the rail system.

In a one hundred and sixteenth aspect, a robot according to the onehundred and fifteenth aspect, wherein the material of the outer coverlayer is ultra-high molecular weight polyethylene.

In a one hundred and seventeenth aspect, a robot according to the onehundred and fifteenth aspect, wherein the material of the outer coverlayer is poly-paraphenylene terephthalamide.

In a one hundred and eighteenth aspect, a robot according to the onehundred and fifteenth aspect, wherein the outer cover layer is furtherfabricated from a second material having a coefficient of friction thatis greater than a coefficient of friction of the material.

One hundred and nineteenth aspect, a robot according to the one hundredand eighteenth aspect, wherein the material and the second material arewoven to fabricate the outer cover layer.

In a one hundred and twentieth aspect, a robot according to any one ofthe one hundred and fifteenth through one hundred and nineteenthaspects, wherein the outer cover layer is further fabricated from asecond material that is electrically conductive.

In a one hundred and twenty first aspect, a robot including a rigidsurface, one or more compliant members attached to the rigid surface,and a sensor device. The sensor device includes an inflatable diaphragmoperable to be disposed around the one or more compliant members, theinflatable diaphragm having a port, and a pressure sensor fluidlycoupled to the port and operable to detect a pressure within theinflatable diaphragm. The one or more compliant members has acoefficient of friction with respect to the sensor device that isgreater than a coefficient of friction between the sensor device and therigid surface.

In a one hundred and twenty second aspect, a robot according to thehundred and twenty first aspect, further including an arm, and the rigidsurface is on the arm.

In a one hundred and twenty third aspect, a robot according to the onehundred and twenty first aspect or the one hundred and twenty secondaspect, wherein the one or more compliant members comprises a foam layerand a friction tape.

In a one hundred and twenty fourth aspect, a robot according to any oneof the one hundred and twenty first through one hundred and twenty thirdaspects, wherein the inflatable diaphragm defines an interior contour,and the one or more compliant members define a surface that correspondsto the interior contour.

In a one hundred and twenty fifth aspect, a robot according to any oneof the one hundred and twenty first through one hundred and twentyfourth aspects, wherein the one or more compliant members comprises afirst compliant member having a non-uniform thickness, a secondcompliant member having a non-uniform thickness.

In a one hundred and twenty sixth aspect, a robot according to the onehundred and twenty fifth aspect, wherein the one or more compliantmembers further comprises a third compliant member having a uniformthickness and a fourth compliant member having a uniform thickness.

In a one hundred and twenty seventh aspect, a robot according to the onehundred and twenty sixth aspect, wherein the one or more compliantmembers are arranged on the rigid surface such that the first compliantmember and the second compliant member are opposite from one another andthe third compliant member and the fourth compliant member are oppositefrom one another.

In a one hundred and twenty eighth aspect, a robot according to any oneof the one hundred and twenty first through one hundred and twentyseventh aspects, wherein the sensor device further includes an array offorce sensors disposed on at least one of an inner surface of theinflatable diaphragm and an outer surface of the inflatable diaphragm,wherein the array of force sensors provides one or more signalsindicative of a location of contact between an object and the inflatablediaphragm.

In a one hundred and twenty ninth aspect, a robot according to the onehundred and twenty eighth aspect, wherein the array of force sensors aredisposed on a surface of the one or more compliant members such that thearray of force sensors contacts the inner surface of the inflatablediaphragm.

In a one hundred and thirtieth aspect, a robot according to the onehundred and twenty ninth aspect, wherein the sensor device furtherincludes a sensor housing, wherein the array of force sensors isdisposed within the sensor housing.

Anyone hundred and thirty first aspect, a robot according to any one ofthe one hundred and twenty first through one hundred and thirtiethaspects, wherein the sensor device further includes an outer cover layerdisposed around the inflatable diaphragm, wherein the outer cover layeris fabricated from a material having a strength of greater than or equalto 35 cN/dtex.

In a one hundred and thirty second aspect, a robot according to the onehundred and thirty first aspect, wherein the material of the outer coverlayer is ultra-high molecular weight polyethylene.

In a one hundred and thirty third aspect, a sensor system includes oneor more compliant members operably to be attached to a rigid surface anda sensor device. The sensor device includes an inflatable diaphragmoperable to be disposed around the one or more compliant members, theinflatable diaphragm having a port, and a pressure sensor fluidlycoupled to the port and operable to detect a pressure within theinflatable diaphragm. The one or more compliant members has acoefficient of friction with respect to the sensor device that isgreater than a coefficient of friction between the sensor device and therigid surface.

In a one hundred and thirty fourth aspect, a sensor system according tothe one hundred and thirty third aspect, wherein the one or morecompliant members includes a foam layer and a friction tape.

In a one hundred and thirty fifth aspect, a sensor system according tothe one hundred and thirty third aspect or the one hundred and thirtyfourth aspect, wherein the inflatable diaphragm defines an interiorcontour, and the one or more compliant members define a surface thatcorresponds to the interior contour.

In a one hundred and thirty sixth aspect, a sensor system according toany one of the one hundred and thirty third through one hundred andthirty fifth aspects, wherein the one or more compliant members includesa first compliant member having a non-uniform thickness, a secondcompliant member having a non-uniform thickness.

In a one hundred and thirty seventh aspect, a sensor system, accordingto the one hundred and thirty sixth aspect, wherein the one or morecompliant members further includes a third compliant member having auniform thickness and a fourth compliant member having a uniformthickness.

In a one hundred and thirty eighth aspect, a sensor system according tothe one hundred and thirty seventh aspect, wherein the one or morecompliant members are arranged on the rigid surface such that the firstcompliant member and the second compliant member are opposite from oneanother and the third compliant member and the fourth compliant memberare opposite from one another.

In a one hundred and thirty ninth aspect, a sensor system according toany one of the one hundred and thirty third through one hundred andthirty eighth aspects, wherein the sensor device further comprises anarray of force sensors disposed on at least one of an inner surface ofthe inflatable diaphragm and an outer surface of the inflatablediaphragm, wherein the array of force sensors provides one or moresignals indicative of a location of contact between an object and theinflatable diaphragm.

In a one hundred and fortieth aspect, a sensor system according to anyone of the one hundred and thirty third three one hundred and thirtyninth aspects, wherein the sensor device further includes an outer coverlayer disposed around the inflatable diaphragm, wherein the outer coverlayer is fabricated from a material having a strength of greater than orequal to 35 cN/dtex.

In a one hundred and forty first aspect, a sensor device includes aninflatable diaphragm operable to be disposed on a member, and an arrayof force sensors disposed about the inflatable diaphragm, wherein thearray of force sensors provides one or more signals indicative of alocation of contact between an object and the inflatable diaphragm.

In a one hundred and forty second aspect, a sensor device according tothe one hundred and forty first aspect, wherein the array of forcesensors are operable to be disposed on a surface of the member such thatthe array of force sensors contacts the inner surface of the inflatablediaphragm.

Anyone hundred and forty third aspect, a sensor device according to theone hundred and forty first aspect or the one hundred and forty secondaspect, further including a sensor housing, wherein the array of forcesensors is disposed within the sensor housing.

In a one hundred and forty fourth aspect, a sensor device according toany one of the one hundred and forty first through one hundred and fortythird aspects, wherein the array of force sensors includes a pluralityof linear force resistors.

In a one hundred and forty fifth aspect, a sensor device according tothe one hundred and forty fourth aspect, wherein each linear forceresistor includes a carbon-doped linear potentiometer.

In a one hundred and forty sixth aspect, a sensor device according toany one of the one hundred and forty first through one hundred and fortyfifth aspects, wherein the array of force sensors includes a pluralityof individual force sensors.

In a one hundred and forty seventh aspect, a sensor device according toany one of the one hundred and forty first through one hundred and fortysixth aspects, wherein one or more force sensors of the array of forcesensors includes a force concentrator.

In a one hundred and forty eighth aspect, a sensor device according toany one of the one hundred and forty first through one hundred and fortyseventh aspects, wherein the inflatable diaphragm further includes aport and the sensor device further includes a pressure sensor and tubingthat fluidly couples the port to the pressure sensor.

In a one hundred and forty ninth aspect, a sensor device according toany one of the one hundred and forty first through one hundred and fortyeighth aspects, further including an outer cover layer disposed aroundthe inflatable diaphragm, wherein the outer cover layer is fabricatedfrom a material having a strength of greater than or equal to 35cN/dtex.

In a one hundred and fiftieth aspect, a sensor device according to theone hundred and forty ninth aspect, wherein the outer cover layerfurther includes one or more additional materials including one or moreof an electrically conductive material and a friction material having acoefficient of friction that is greater than a coefficient of frictionof the material.

In a one hundred and fifty first aspect, a robot including at least onemember and a sensor device including an inflatable diaphragm disposed onthe at least one member, and an array of force sensors disposed aboutthe inflatable diaphragm, wherein the array of force sensors providesone or more signals indicative of a location of contact between anobject and the inflatable diaphragm.

In a hundred and fifty second aspect, a robot according to the onehundred and fifty first aspect, wherein the array of force sensors aredisposed on a surface of the at least one member such that the array offorce sensors contacts the inner surface of the inflatable diaphragm.

In a one hundred and fifty third aspect, a robot according to the onehundred and fifty first or the one hundred and fifty second aspect,wherein the sensor device further comprises a sensor housing, whereinthe array of force sensors is disposed within the sensor housing.

In a one hundred and fifty fourth aspect, a robot according to any oneof the one hundred and fifty first through one hundred and fifty thirdaspects, wherein the array of force sensors includes a plurality oflinear force resistors.

In a one hundred and fifty fifth aspect, a robot according to the onehundred and fifty fourth aspect, wherein each linear force resistorincludes a carbon-doped linear potentiometer.

In a one hundred and fifty sixth aspect, a robot according to any one ofthe one hundred and fifty first through one hundred and fifty fifthaspects, wherein the array of force sensors comprises a plurality ofindividual force sensors.

In a one hundred and fifty seventh aspect, a robot according to any oneof the one hundred and fifty first through one hundred and fifty sixthaspects, wherein one or more force sensors of the array of force sensorsincludes a force concentrator.

In a one hundred and fifty eighth aspect, a robot according to any oneof the one hundred and fifty first through one hundred and fifty seventhaspects, wherein the inflatable diaphragm further includes a port, andthe sensor device further includes a pressure sensor and tubing, whereinthe tubing fluidly couples the port to the pressure sensor.

In a one hundred and fifty ninth aspect, a robot according to any one ofthe one hundred and fifty first through one hundred and fifty eighthaspects, further including an outer cover layer disposed around theinflatable diaphragm, wherein the outer cover layer is fabricated from amaterial having a strength of greater than or equal to 35 cN/dtex.

In a one hundred and sixtieth aspect, a robot according to any one ofthe one hundred and fifty first through one hundred and fifty ninthaspects, further including one or more compliant members disposedbetween a surface of the at least one member and the inflatablediaphragm.

In a one hundred and sixty first aspect, a robot includes a rail system,a body structure coupled to the rail system, a first arm coupled to afirst side of the body structure, one or more first arm actuatorsproviding the first arm with multiple degrees of freedom, a second armcoupled to a second side of the body structure, one or more second armactuators providing the second arm with multiple degrees of freedom, anda lift actuator operable to move the body structure along the railsystem. The one or more first arm actuators and the one or more secondarm actuators are operable to wrap the first arm and the second armaround an object and hold the object against the body structure. Thelift actuator is operable to move the body structure such that theobject is lifted on the rail system.

In a one hundred and sixty second aspect, a robot according to the onehundred and sixty first aspect, wherein each of the one or more firstarm actuators and the one or more second arm actuators includes ashoulder actuator that couples the first arm and the second arm to thebody structure, an elbow actuator, and a wrist actuator.

In a one hundred and sixty third aspect, a robot according to the onehundred and sixty first aspect or the one hundred and sixty secondaspect, further including a first end effector coupled to the wristactuator of the one or more first arm actuators and a second endeffector coupled to the wrist actuator of the one or more second armactuators.

In a one hundred and sixty fourth aspect, a robot according to the onehundred and sixty third aspect, wherein the first end effector and thesecond end effector each comprise a deformable membrane.

In a one hundred and sixty fifth aspect, a robot according to any one ofthe one hundred and sixty first aspect through one hundred and sixtyfourth aspect, wherein the body structure includes one or more forcesensors operable to detect a force applied to the body structure.

In a one hundred and sixty sixth aspect, a robot according to the onehundred and sixty fifth aspect, wherein the one or more force sensorsincludes an array of flexible tactile sensors.

In a one hundred and sixty seventh aspect, a robot according to the onehundred and sixty sixth aspect, wherein each force sensor of the arrayof flexible tactile sensors is operable to detect a force magnitude anda force direction.

In a one hundred and sixty eighth aspect, a robot according to the onehundred and sixty seventh aspect, wherein each flexible tactile sensorincludes a pliable layer.

In a one hundred and sixty ninth aspect, a robot according to the onehundred and sixty seventh aspect, further including a processor, whereinthe processor is operable to receive one or more signals from the arrayof force sensors and, from the one or more signals, determine a geometryof the object.

In a one hundred and seventieth aspect, a robot according to the onehundred and sixty fifth aspect, further including a friction materialthat covers the one or more force sensors.

In a one hundred and seventy first aspect, a robot according to any oneof the one hundred and sixty first through one hundred and seventiethaspects, further including one or more deformable sensors positioned onat least one of the first arm and the second arm.

In a one hundred and seventy second aspect, a robot according to the onehundred and seventy first aspect, wherein the one or more deformablesensors includes a deformable membrane.

In a one hundred and seventy third aspects, a robot according to any oneof the one hundred and sixty first through one hundred and seventysecond aspects, further including one or more control members operableto be grasped by a user such that the user may move the robot.

In a one hundred and seventy fourth aspect, a robot including a railsystem, a body structure coupled to the rail system, the body structureincluding one or more force sensors operable to detect a force appliedto the body structure, a first arm coupled to a first side of the bodystructure, a plurality of first arm actuators providing the first armwith multiple degrees of freedom, a second arm coupled to a second sideof the body structure, a plurality of second arm actuators providing thesecond arm with multiple degrees of freedom, and a lift actuatoroperable to move the body structure along the rail system. The pluralityof first arm actuators and the plurality of second arm actuators areoperable to wrap the first arm and the second arm around an object andhold the object against the body structure. The lift actuator isoperable to move the body structure such that the object is lifted onthe rail system.

In a one hundred and seventy fifth aspect, a robot according to the onehundred and seventy fourth aspect, wherein each of the plurality offirst arm actuators and the plurality of second arm actuators includes ashoulder actuator that couples the first arm and the second arm to thebody structure, an elbow actuator, and a wrist actuator.

In a one hundred and seventy sixth aspect, a robot according to the onehundred and seventy fifth aspect, wherein the one or more force sensorsincludes an array of flexible tactile sensors.

In a one hundred and seventy seventh aspect, a robot according to theone hundred and seventy sixth aspect, wherein each force sensor of thearray of flexible tactile sensors is operable to detect a forcemagnitude and a force direction.

In a one hundred and seventy eighth aspect, a robot according to the onehundred and seventy seventh aspect, wherein each flexible tactile sensorincludes a pliable layer.

In a one hundred and seventy ninth aspect, a robot according to the onehundred and seventy seventh aspect, further including a processor,wherein the processor is operable to receive one or more signals fromthe array of force sensors and, from the one or more signals, determinea geometry of the object.

In a one hundred and eightieth aspect, a robot according to any one ofthe one hundred and seventy fourth through one hundred and seventy ninthaspects, further including one or more deformable sensors positioned onat least one of the first arm and the second arm.

While particular embodiments have been illustrated and described herein,it should be understood that various other changes and modifications maybe made without departing from the spirit and scope of the claimedsubject matter. Moreover, although various aspects of the claimedsubject matter have been described herein, such aspects need not beutilized in combination. It is therefore intended that the appendedclaims cover all such changes and modifications that are within thescope of the claimed subject matter.

1. A sensor assembly comprising: a compliant substrate assemblycomprising: a base layer; and a deformable layer heat-sealed to the baselayer such that the base layer and the deformable layer define at leastone inflatable chamber; a first member proximate to a first edge of thecompliant substrate assembly; a second member proximate to a second edgeof the compliant substrate assembly, wherein the second edge is oppositethe first edge; and at least one pressure sensor fluidly coupled to theat least one inflatable chamber and operable to produce a signalindicative of a pressure within the at least one inflatable chamber. 2.The sensor assembly of claim 1, wherein the at least one inflatablechamber is operable to be filled with a gas.
 3. The sensor assembly ofclaim 2, further comprising a tubing that fluidly couples the at leastone inflatable chamber to the at least one pressure sensor.
 4. Thesensor assembly of claim 1, wherein the base layer is fabricated from afirst material and the deformable layer is fabricated from a secondmaterial that is different from the first material.
 5. The sensorassembly of claim 1, wherein the at least one inflatable chambercomprises an array of inflatable chambers.
 6. The sensor assembly ofclaim 5, wherein the at least one pressure sensor comprises a pluralityof pressure sensors fluidly coupled to the array of inflatable chambers.7. The sensor assembly of claim 1, wherein the first member and thesecond member are rods.
 8. A structure for receiving a compliantsubstrate assembly, the structure comprising: an outer surface; a firstset of engagement features extending from a first location of the outersurface, wherein the first set of engagement features are configured toreceive a first member of the compliant substrate assembly; and a secondset of engagement features extending from a second location of the outersurface that is offset from the first location by a distance, whereinthe second set of engagement features are configured to receive a secondmember of the compliant substrate assembly.
 9. The structure of claim 8,wherein the distance is greater than a length of the compliant substrateassembly as measured from the first member to the second member.
 10. Thestructure of claim 8, wherein the first set of engagement featurescomprises two or more first hooks and the second set of engagementfeatures comprises two or more second hooks.
 11. The structure of claim8, wherein the structure is at least a portion of a robot arm.
 12. Asensor assembly comprising: a base structure comprising: an outersurface; a first set of engagement features extending from a firstlocation of the outer surface; and a second set of engagement featuresextending from a second location of the outer surface that is offsetfrom the first location by a distance; a compliant substrate assemblycomprising: a base layer; a deformable layer heat-sealed to the baselayer such that the base layer and the deformable layer define at leastone inflatable chamber; a first member proximate to a first edge of thecompliant substrate assembly, wherein the first member is held by thefirst set of engagement features; and a second member proximate to asecond edge of the compliant substrate assembly, wherein the second edgeis opposite the first edge and the second member is held by the secondset of engagement features such that the compliant substrate assembly isstretched over at least a portion of the base structure; and at leastone pressure sensor fluidly coupled to the at least one inflatablechamber and operable to produce a signal indicative of a pressure withinthe at least one inflatable chamber.
 13. The sensor assembly of claim12, wherein the at least one inflatable chamber is operable to be filledwith a gas.
 14. The sensor assembly of claim 13, further comprising atubing that fluidly couples the at least one inflatable chamber to theat least one pressure sensor.
 15. The sensor assembly of claim 12,wherein the base layer is fabricated from a first material and thedeformable layer is fabricated from a second material that is differentfrom the first material.
 16. The sensor assembly of claim 12, whereinthe at least one inflatable chamber comprises an array of inflatablechambers.
 17. The sensor assembly of claim 16, wherein the at least onepressure sensor comprises a plurality of pressure sensors fluidlycoupled to the array of inflatable chambers.
 18. The sensor assembly ofclaim 12, wherein the first member and the second member are rods. 19.The sensor assembly of claim 12, wherein the distance is greater than alength of the compliant substrate assembly as measured from the firstmember to the second member.
 20. The sensor assembly of claim 12,wherein the first set of engagement features comprises two or more firsthooks and the second set of engagement features comprises two or moresecond hooks.